Reliability and Maintenance Management

Code

5016

Academic unit

Faculdade de Ciências e Tecnologia

Department

Departamento de Engenharia Mecânica e Industrial

Credits

6.0

Teacher in charge

Helena Victorovna Guitiss Navas, Rogério Salema Araújo Puga Leal

Weekly hours

4

Total hours

100

Teaching language

Português

Objectives

1. To provide the statistical knowledge concerning lifetime data in order to identify the appropriate methods study and evaluate the Reliability of Repairable Systems and Components.
2. To understand the advantages and constraints of several statistical models.
3. Utilization of statistical models for decision making in Maintenance Management leading to the development of reliability based maintenance within a philosophy of Total Productive Maintenance.

Prerequisites

The Quality Planning and Controlcourse provides an important background.

Subject matter

1. Introduction

1.1. Reliability Concept

1.2. Lifetime Data Analysis

1.3. Components Reliability

1.4. Repairable and not Repairable Systems

1.5. Poisson Process

1.6. Total Productive Maintenance

2   Statistics of the Failures

2.1 Censured and non-Censured Data

2.2 Hazard Function versus Probability Density Function

2.3   Lognormal Distribution

2.4   Weibull and Gumbel Distribution  

2.5. Gamma Distribution

3   Repairable Systems

3.1. Stochastic Point  Processes

3.1.1. Tests of Trend and Independence

3.1.2 Homogeneous Poisson Processes

3.1.3. Nonhomogeneuos Poisson Processes

3.1.4. Branching Poisson Processes

3.1.5. Renewal Processes

3.1.6. Superimposed Renewal Processes

3.2. Regression Models

3.2.1. Accelerated Time Models

3.2.2. Proportional Hazard Model

4   Maintenance Management

4.1. Planning and Programming of Maintenance

 4.1.1. Codification of the maintenance artifacts

4.1.2. Documentation and data for planning

4.1.3. Maintenance Planning

4.1.4. Planning of the maintenance of an installation or complex equipment

4.1.5. Preparation of work

4.1.6. Maintenance control

4.1.7. Maintenance budget

4.2. - Maintenance Organization  and Human resources

4.2.1. Maintenance in the organisation''''s structure

4.2.2. Specialization and Polyvalence

4.2.3. Motivation and teamwork

4.2.4. Formation

4.3. Strategy of maintenance

4.3.1. Alignment  the  Maintenance''''s Strategy with Company''''s   Strategy

4.3.2. Definition and Implementation of  Maintenance Policies

4.3.3. Maintenance and TQM

4.3.4. The maintenance and New Investments

4.3.5. Internalor External Resources

4.4. Costs associated to maintenance

4.4.1. Factors of cost in maintenance

4.4.2. Elements for calculation of costs

4.4.3. Direct costs

4.4.4. Indirect costs

4.4.5. The decisions of maintenance based in costs

4.5. Management of surpluses

4.6. On Line Maintenance

4.6.1. Concept

4.6.2. Methodology

4.6.3.  Condition Control

4.7. Total Productive Maintenance (TPM)

4.7.1. Concept, objectives, areas of application and advantages

4.7.2. Methodology

4.7.3. Statistical tools in TPM

4.7.4. The objective "Zero-Failures"

4.8. Systems of Information for Maintenance Management

4.8.1. The importance of historical registers

4.8.2. Marks for maintenance management

4.8.3. Informatics systems for maintenance management

Bibliography

1. Ascher, H. and Feingold, H. (1984), Repairable System Reliability. Modelling, Inference, Misconceptions and Their Causes, Marcel Dekker, New York.
2. Crowder, M.J., Kimber, A.C., Smith, R.L. and Sweeting (1994), Statistical Analysis of Reliability Data, Chapman and Hall, London.
3. Guimarães, R.C. e Cabral, J.S.(1997), Estatística, MacGraw-Hill.
4. Ho, S.K. (1995), TQM - an Integrated Approach, Kogan Page Limited, UK.
5. Krishnamoorthi, K.S. (1992), Reliability Methods for Engineers, ASQC Quality Press
6. O’Connor, P. D. T. (1991), Practical Reliability Engineering, Wiley, New York..
7. Smith, S. (1993), Reliability Centred Maintenance, Reuters

Teaching method

Teaching strategy is based on a combination of expositive approaches with simulated practice. The course’s project is aimed to develop student’s technical skills as well as their ability to perform teamwork.

Evaluation method

• The evaluation of students is done through the implementation of two mini-tests (T₁, T₂), one practical work (TP) and exam.
• Admission to the examination is obtained by the classification of at least 7 in the practical work.
• The admission to examination is valid for one year.
• The approval requires reaching at least 10 in the final exam.
• The excuse of exam presumes obtaining the weighted average of the two mini-tests and practical work of at least 10 values​​.

(T₁ + T₂ + TP) / 3 ≥ 10

Courses

• Industrial Engineering and Management